The efficiency of stationary energy generating turbomachines and the CO2-emissions produced by them can be influenced by the design of the blade components which are subjected to high loads. However the surfaces of the complex 3D-geometries of compressors and turbines are subjected to particularly high load due to increases in operating temperature and corrosion. The service life of these components can be prolonged to match the load by the use of high-alloy steel, nickel-based alloys or thermal protective coatings. The Fraunhofer IPT develops adaptive process chains which are capable of producing complex, new parts efficiently and of repairing unavoidable damage sustained by gas turbine blades with complex shapes and which are often made of mono-crystalline nickel-based alloys, thus saving costs over the entire life cycle of the turbine.

The focus is on your components

Blade clusters

Stationary blade clusters are built in between rotating units where their improved sealing concepts reduce the gap losses of the flow. The high level of geometrical complexity of the blade clusters restricts the manufacturing process as the flow surfaces are only partially accessible. Smart process design permits further increases in stability, accuracy and efficiency in manufacturing processes.

Individual blade

One of the production-engineering challenges facing the energy sector relates to the thin-walled steam turbine blades, which can be as long as 2.2 meters. Individual blades made of high temperature resistant materials will be crucial to the efficiency of future turbomachinery. These premium-quality cost-intensive components necessarily sustain high levels of wear during operation. The Fraunhofer IPT develops flexible process chains enabling even seriously damaged components to be repaired, ready for further reliable use thus prolonging the life cycle of the parts whilst conserving valuable resources.